Space filling material and space filling structure, and methods for using those

Abstract

Provided are a space filling material and a space filling structure capable of filling a predetermined space for various purposes, and method for using those. A space filling material ( 11 ) includes reinforcing fibers as an expansion material and a resin. The reinforcing fibers form a plurality of intersections and are bonded with the resin at at least one of the intersections. Heating of the space filling material causes an expansion stress in at least a thickness direction (X) such that the space filling material fills a predetermined space ( 13 ). For example, the space filling material may contain the resin at a volume ratio of 15 to 95 vol % based on a total volume of the reinforcing fibers and the resin.

What is claimed is: 
     
       1. A space filling material comprising:
 reinforcing fibers as an expansion material, the reinforcing fibers forming a plurality of intersections, and, 
 a resin bonding at least one of the intersections; 
 the space filling material generating an expansion stress upon heating in at least a thickness direction such that the space filling material fills a predetermined space, wherein: 
 the resin is a thermoplastic resin; and 
 the thermoplastic resin has a glass transition temperature of 100° C. or higher. 
 
     
     
       2. The space filling material according to  claim 1 , wherein the space filling material contains the resin at a volume ratio of 15 to 95 vol % based on a total volume of the reinforcing fibers and the resin. 
     
     
       3. A space filling material comprising:
 reinforcing fibers as an expansion material, the reinforcing fibers forming a plurality of intersections, and, 
 a resin bonding at least one of the intersections; and 
 the space filling material generating an expansion stress upon heating in at least a thickness direction such that the space filling material fills a predetermined space 
 wherein the reinforcing fibers are in bent forms each receiving a bending load; and 
 softening of the resin releases the bending load to make the space filling material to be expanded. 
 
     
     
       4. The space filling material according to  claim 1 , wherein the space filling material has an expansion ratio of 105% or more at a constant load in the thickness direction. 
     
     
       5. The space filling material according to  claim 1 , wherein the space filling material after expanded has a deformation ratio of −10% to 10% in a direction perpendicular to the thickness direction. 
     
     
       6. A space filling material comprising:
 reinforcing fibers as an expansion material, the reinforcing fibers forming a plurality of intersections, and, 
 a resin bonding at least one of the intersections; and 
 the space filling material generating an expansion stress upon heating in at least a thickness direction such that the space filling material fills a predetermined space wherein: 
 the resin is a thermoplastic resin; and 
 the thermoplastic resin is at least one of thermoplastic resin selected from a group consisting of a thermoplastic polyimide-based resin, a polyether ketone-based resin, a semi-aromatic polyamide-based resin, a polycarbonate-based resin, a liquid crystal polyester-based resin, a polysulfone-based resin, and a polytetrafluoroethylene-based resin. 
 
     
     
       7. The space filling material according to  claim 1 , wherein the reinforcing fibers have a fiber length of 3 to 100 mm. 
     
     
       8. The space filling material according to  claim 1 , wherein the reinforcing fibers are insulative fibers. 
     
     
       9. The space filling material according to  claim 1 , wherein the space filling material has a porosity of 3 to 75%. 
     
     
       10. The space filling material according to  claim 1 , wherein the space filling material has a density of 0.5 to 10 g/cm 3 . 
     
     
       11. The space filling material according to  claim 1 , wherein the space filling material is used for fixing a material to be fixed in the predetermined space. 
     
     
       12. A space filling structure comprising the space filling material as recited in  claim 11  and a material to be fixed, the material(s) being integrated in contact with at least a part of the space filling material. 
     
     
       13. The space filling structure according to  claim 12 , wherein the material to be fixed is sandwiched between the space filling materials. 
     
     
       14. A method of using the space filling material as recited in  claim 1 , the method comprising:
 heating the space filling material at a temperature of softening temperature of the resin or higher so as to expand the space filling material in the predetermined space. 
 
     
     
       15. The method according to  claim 14  comprising inserting the space filling material into the predetermined space. 
     
     
       16. A method of using the space filling material as recited in  claim 1 , the method comprising:
 heating the space filling material at a temperature of softening temperature of the resin or higher so as to expand the space filling material(s) in the predetermined space and fix a material to be fixed. 
 
     
     
       17. The method according to  claim 16  comprising inserting the space filling material and/or the material to be fixed into the predetermined space. 
     
     
       18. A method of using the space filling structure as recited in  claim 12 , the method comprising:
 heating the space filling material at a temperature of softening temperature of the resin or higher so as to expand the space filling material(s) in the predetermined space and fix the material to be fixed. 
 
     
     
       19. The method according to  claim 18  comprising inserting the space filling structure into the predetermined space. 
     
     
       20. The method according to  claim 14 , wherein the expanded space filling material has a porosity of 30 to 95%. 
     
     
       21. The method according to  claim 14 , wherein the expanded space filling material has a continuous porous structure. 
     
     
       22. The method according to  claim 14 , wherein the expanded space filling material has a density of 0.1 to 1.5 g/cm 3 .